841 Operating Instructions
IMPORTANT READ CAREFULLY BEFORE USE KEEP TO CONSULT LATER All rights reserved. Property of Dürkopp Adler AG and protected by copyright. Any reuse of these contents, including extracts, is prohibited without the prior written approval of Dürkopp Adler AG.
Table of Contents 1 About this operating manual ..................................................... 3 1.1 1.2 1.3 1.4 1.5 1.5.1 1.5.2 Scope of the operating manual..................................................... 3 For whom is this operating manual intended? .............................. 3 Representation conventions – symbols and characters ............... 3 Other documents .......................................................................... 5 Liability......................................
Table of Contents 2 6 Settings via the software ......................................................... 37 6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.5 6.6 6.6.1 6.6.2 6.6.3 6.6.4 6.6.5 6.6.6 6.6.7 6.6.8 6.7 6.7.1 6.7.2 6.7.3 6.7.4 Indexer program parameters ...................................................... 37 Manual sewing mode parameters .............................................. 38 Setting the needle thread tension ............................................... 38 Setting the buttonhole program .....
About this operating manual 1 About this operating manual This operating manual for sewing machine 841-100-01 was compiled with the utmost care. It contains information and notes in order to ensure longterm and reliable operation. Please contact us if you find any discrepancies or have any suggestions 5.13 Customer Service, page 36. Consider this operating manual part of the product and keep it on hand at all times. Be sure to read the manual completely before using the product for the first time.
About this operating manual Steps to be performed when operating the machine (sewing and equipping) Steps to be performed for servicing, maintenance, and installation Steps to be performed via the software control panel 1. The individual steps are numbered: 1. First step 2. 2. Second step ... The sequence of the steps must always be followed. • Lists are identified by bullet points. Result of performing an operation Change to the machine or in the display.
About this operating manual 1.4 Other documents This equipment includes components from other manufacturers. Each manufacturer has performed a hazard assessment for these purchased parts and confirmed their design compliance with applicable European and national regulations. The proper use of these components is described in each manufacturer's manual. 1.5 Liability All information in this operating manual was compiled with consideration to the state of the art, and applicable standards and regulations.
About this operating manual Only authorized/trained personnel may operate the machine. The manufacturer cannot be held liable for damages resulting from improper use. WARNING Risk of electric shock, crushing and punctures! Improper use can result in injury. Please observe all instructions in the manual. ATTENTION Improper use can result in material damage. Please observe all instructions in the manual. 6 Operating Instructions 841 - 00.
Technical Specifications 2 Technical Specifications 2.1 Sewing unit THe Dürkopp-Adler 841-100-01 is a sewing unit for automatic sewing of buttonholes on the fronts of shirts and blouses. The sewing unit is made up of independent functional units like infeed,feed and sewing stations and stacker that enable fully overlapping work procedures. In the infeed unit, the front section (sewing material) is placed along the a stop and fixed on markings using a vacuum.
Technical Specifications 2.3 Declaration of conformity The machine complies with the European regulations specified in the declaration of conformity or in the installation declaration. 2.4 Additional equipment A flexible system of additional equipment allows the sewing machine to be optimally equipped for any application at low cost.
Technical Specifications 2.
Technical Specifications 10 Operating Instructions 841 - 00.
Safety information 3 Safety information This section contains basic information for your safety. Read the instructions carefully before setting up or operating the machine. Make sure to follow the information included in this section. Failure to do so can result in serious injury and damage to the machine. 3.1 Basic safety instructions The machine may be used only as described in this operating manual. The operating manual should be available at the machine's location at all times.
Safety information Maintenance work and repairs may only be carried out by qualified technicians. Work on electrical equipment may only be carried out by qualified specialists. Only authorized persons may work on the machine. Every person who works on the machine must have read the operating manual first. Operation Inspect the machine while in use for any externally visible damage. Stop working if you notice any changes to the machine. Report any changes to your supervisor.
Safety information Symbols The following symbols indicate the type of risk to personnel: Symbol Type of danger General risk Risk of electric shock Risk of puncturing Risk of crushing Examples Examples of the layout of the warnings in the text: DANGER Type and source of risk Consequences of non-observance Measures for avoiding the risk This is what a warning looks like for a hazard that will result in serious injury or even death if ignored WARNING Type and source of risk Consequences of non-observan
Safety information CAUTION Type and source of risk Consequences of non-observance Measures for avoiding the risk This is what a warning looks like for a hazard that could result in moderate or minor injury if the warning is ignored. CAUTION Type and source of risk Measures for avoiding the risk This is a warning note for a hazard that could result in environmental damage if ignored.
Machine Description 4 Machine Description 4.1 Sewing unit Figure 1: Sewing unit ① ② ③ ⑥ ⑤ ④ (1) - Sewing machine upper part (2) - Infeed device (3) - Stacker (4) - Knee lever (5) - Vacuum fan (additional equipment) (6) - Control panel 4.2 Control panel The controller is programmed via the control panel and the functions set for the relevant seam. This is done by pressing the relevant buttons or by changing the parameters. The parameters and the relevant values are shown on the display.
Machine Description Figure 2: Control panel Key Function • Open/close stacker. If no input field is activated: • Change to higher-level menu. If no input field is activated: • Step-for-step mode for repairs. If an input field is activated: • Change between the tenths, ones or tens position. • Change between the rows in the menus. The selected row is highlighted with a dark background.
Machine Description Key Function • Controller switches from sewing mode to programming mode. The buttonhole parameters may be modified. • Controller switches from sewing mode or programming mode to index programming mode. • Change mode: Press x1: Controller switches to manual sewing mode. Press x2: Controller switches to technician mode. Technician mode can only be activated after entering a code. Basic machine parameters can be set here and diagnosis and setting programs opened up.
Machine Description 4.3 Software description Symbol 18 Parameters Meaning Index program N1 • Selection of indexer program to be sewn • Program numbers 1 to 99.
Operation 5 Operation 5.1 Switching the unit on and off For the sewing unit to be ready for operation, the infeed unit must be moved to reference position after being switched on. The reference run is necessary in order to obtain a defined starting position for the infeed unit. WARNING Risk of injury Crushing injuries from moving parts. During the reference run, do not reach into the movement area of the infeed unit.
Operation 5.2 Threading in the needle thread CAUTION Risk of injury from the point of the needle and moving parts Only thread the needle thread with the sewing machine switched off. Figure 4: Threading in the needle thread 1. Fit the thread reels on the thread reel holder. 2. Press the Safe Stop key. 3. Thread needle thread. 20 Operating Instructions 841 - 00.
Operation 5.3 Winding the hook thread Figure 5: Threading the hook thread ① ② ③ (1) - Bobbin lever (2) - Winder (3) - Thread clamp 1. Fit the thread reel on the thread reel holder. 2. Fit the bobbin on the bobbin winder (2). 3. Thread the hook thread as shown in the following figure. 4. Wind the hook thread clockwise approx. 5 x around the bobbin core. 5. Pivot the bobbin lever (1) towards the bobbin so it engages. The hook thread is automatically wound onto the bobbin.
Operation 5.4 Changing the bobbin CAUTION Risk of injury from the point of the needle and moving parts Only change the bobbin when the sewing unit is switched off. Figure 6: Changing the bobbin ① ⑦ ⑥ ② ③ ⑤ ④ (1) - Hanger (2) - Slot (3) - Slot (4) - Spring (5) - Screw (6) - Slot (7) - Slot Removing an empty bobbin 1. Open the hook compartment cover. 2. Flip the hook up (1). 3. Remove the bobbin housing upper section with the bobbin. 4. Remove the empty bobbin from the bobbin housing upper section.
Operation over the rear of the hook) or through slot (3) for a whip-stitch buttonhole (less thread). 4. Cut off the hook thread you have inserted on the opposite side of the hook using the cutter. Setting the hook thread tension 1. Turn screw (5) so that the bobbin housing is lowered slowly due to its own weight while holding the end of the thread steady. With whip-stitch buttonholes, greater tension is required. Inserting the bobbin housing upper section 1. Insert the bobbin case with the bobbin.
Operation Figure 7: Changing the needle ① (1) - Screw 1. Loosen the screw (1). 2. Pull the needle out towards the bottom. 3. Insert the new needle and push it right to the top. 4. Align the needle so that its scarf/groove is turned away from the cutter. 5. Tighten the screw (1). 5.6 Setting the sewing basket pressure The sewing basket pressure is set to the maximum value. This pressure only needs to be reduced for sensitive sewing materials.
Operation 5.7 Setting the sewing basket fan height A sewing basket fan height of 12 mm is set in the factory. The sewing basket fan height only needs to be changed for certain types of sewing material. Figure 9: Setting the sewing basket fan height ① ② ③ (1) - Screw (2) - Screw (3) - Setscrew 1. Switch off the machine. 2. Undo screws (1) and (2). 3. To increase the sewing basket fan height: Turn the threaded pin (3) clockwise. 4.
Operation Figure 10: Changing the cutter ① ② (1) - Screw (2) Cutter 1. Press the Safe Stop key. 2. Loosen the screw (2). 3. Remove the cutter (3). 4. Insert the new cutter and push it right to the top. 5. Tighten the screw (1). Important If the cut does not run central in the buttonhole or is not parallel to the buttonhole seams, the cutter will have to be realigned. For more information see Service manual. 26 Operating Instructions 841 - 00.
Operation 5.9 Setting the buttonhole distance to the front edge The distance of the buttonholes to the lay edge can be within a range between 10 and 20 mm. Figure 11: Setting the buttonhole distance ① ② (1) - Adjusting screw (2) - Pointer 1. Using the setting wheel (1) set the distance of the buttonholes to the lay edge. The pointer (2) can be used as orientation for how the distance is set. 5.10 Marking the lay points 1.
Operation 5.11.2 Checking the buttonhole setting 1. Use the buttons to select the index program. 2. Press the F key once to switch to manual sewing mode and sew a buttonhole or to check the settings for the current buttonhole. 3. Insert the material to be sewn. 4. When sewing the first buttonhole: Hold the end of the thread. 5. Press the S key. Sewing process starts. 6. Check the buttonhole settings and adjust if necessary. 5.11.3 Sewing the buttonhole placket 1.
Operation • Press the OK key. • Remove the material to be sewn • Press the key if sewing material is not to be reinserted. • Confirm sewing over, cf. Step 1. Jumping from buttonhole to buttonhole (mode B) 1. Press the Safe Stop key. 2. Insert the needle thread, see ( 5.2 Threading in the needle thread, page 20). 3. Release the Safe Stop key. 4. Using the buttons, jump from buttonhole to buttonhole. 5. Press the OK key to start the sewing process. 6. Press the ESC key to cancel the sewing process.
Operation 5.11.6 Removing the sewing material from the stacker 1. Press the key. Stacker opens. 2. Remove the sewing material. 3. Press the key. Stacker closes. 5.11.7 Working with dongle data Buttonhole data, sequence data and machine data can be loaded using a data dongle and stored. For more information see Service manual. 5.12 Maintenance This section describes simple maintenance work that needs to be carried out on a regular basis.
Operation • Area under hook • Bobbin housing • Thread cutter Cleaning steps 1. Remove any dust and thread remains using a compressed air gun or a brush. 2. Clean the vacuum pump (additional equipment). 5.12.2 Lubrication WARNING Risk of injuries due to contact with oil. Contact with oil can cause irritation, rashes, allergies or skin injuries. ALWAYS avoid long-term contact with oil. ALWAYS thoroughly wash the affected areas if contact with oil occurs. ATTENTION Risk of environmental damage from oil.
Operation DA 10 can be obtained under the following part number at DA sales offices: • 9047 000011 – 250 ml • 9047 000012 – 1 l • 9047 000013 – 2 l • 9047 000014 – 5 l 5.12.3 Lubrication of the upper part of the machine The central oil lubrication system supplies all bearing positions with oil from the reservoir. ATTENTION Machine damage due to incorrect oil level Too little or too much oil can result in damages to the machine. Check the oil level every day and top up the oil, if necessary.
Operation ATTENTION Machine damage due to incorrect pressure Incorrect pressure can result in damage to the machine. Make sure that the machine is only used when the operating pressure is set correctly. Figure 13: Setting operating pressure 1 6 4 8 2 10 0 (1) - Adjustment knob 2 (2) - Pressure indicator Setting steps 1. Pull the adjustment knob (1) up. 2.
Operation ATTENTION Machine damage due to too much water Too much water can result in damage to the machine. Check the water level every day and drain water, if necessary. Figure 14: Draining the water condensation 6 4 8 2 10 0 1 2 3 (1) - Filter element (2) - Water separator (3) - Drain screw Maintenance steps 1. Place the collection tray under the drain screw (3). 2. Unscrew the drain screw (3) completely. 3. Allow water to drain into the collection tray. 4. Tighten the drain screw (3).
Operation Figure 15: Cleaning the filter element 6 4 8 2 10 0 1 2 3 (1) - Filter element (2) - Water separator (3) - Drain screw Cleaning steps 1. Drain the water condensation ( page 33). 2. Unscrew the water separator (2). 3. Unscrew the filter element (1). 4. Blow out the filter element (1) using a compressed air gun. 5. Wash out the filter tray using benzine. 6. Tighten the filter element (1). 7. Tighten the water separator (2). 8. Tighten the drain screw (3). 5.12.
Operation 5.13 Customer Service Contact for repairs if machine is damaged: Dürkopp Adler AG Potsdamer Str. 190 33719 Bielefeld, Germany Tel. +49 (0) 180 5 383 756 Fax +49 (0) 521 925 2594 E-mail: service@duerkopp-adler.com Internet: www.duerkopp-adler.com 36 Operating Instructions 841 - 00.
Settings via the software 6 Settings via the software 6.1 Indexer program parameters Symbol Parameters Values Meaning Indexer program (Index prg.) 1 … 99 • Selection of indexer program to be sewn Sequence On/Off • Asks whether the same buttonhole should be always be sewn or a selection of several buttonholes. • On: several buttonholes are sewn • Off: a single buttonhole is sewn Buttonhole program 1 … 52 number (Buttonhole no.
Settings via the software 6.2 Manual sewing mode parameters Symbol Parameters Meaning Basket • Using the OK button, the sewing basket can be vented and lowered. • The same function is applied by pressing the P button. Start • Using the OK button, the sewing process can be started. The sewing basket is lowered and the currently selected buttonhole is sewn. • The same function is applied by pressing the S button. 6.3 Setting the needle thread tension 1. Switch the machine on and reference it. 2.
Settings via the software Overall the needle thread tension can be increased up to 5 times. Individual adjustments will have to be made for how often the needle thread tension is increased and after which steps in order to obtain a good quality buttonhole.
Settings via the software 6.4 Setting the buttonhole program 6.4.1 Buttonhole setup Figure 16: Buttonhole setup ⑤ ① ⑩ ③ ④ ⑥ ⑨ ⑪ ② ⑫ 40 ⑧ ⑦ ⑬ Pos.
Settings via the software 6.4.2 Principles Parameters Meaning Forward and return seam • The return seam is symmetrical to the forward seam using the cutting length as an axis of symmetry. Buttonhole width = tacking width • The buttonhole width setting automatically specifies the tacking width. The tacking width can be adjusted via the parameters offset l and offset r in the relevant tacking menu. Tacking • The final tacking length is the first tacking length if both tackings are identical.
Settings via the software Symbol Parameters Values Lower tacking P7 Meaning • Set the final tacking Double run P8 On/Off • Switches double sewing of the entire buttonhole on or off Knit fabric P9 On/Off • Switch knit fabric mode on/off Basting stitches P10* • Show number of basting stitches and properties Zigzag runs (ZZ runs) P11* • Set 2nd zigzag run and show properties Cut P12* • Cutting in the last run • Cutting in the last but one run • Cutting during both runs Copying off P13 0 … 50
Settings via the software Symbol Parameters Values Meaning Length after cut (see below) P4.7 (1.8 mm – P7.3) 1. Correction of position of first tacking at end of cut –5.9 mm 2. Additional buttonhole seam length after cut with asymmetrical opening cut within the buttonhole Cut correction X (X-Offset) P4.8 –0.5...+0.5 mm • Location of cut within the buttonhole in x-direction Correction right (corr.r.) P4.9 –0.3...+0.
Settings via the software 6.6.1 Cross tacking (horizontal) parameters, tacking type A Symbol Parameters Values Meaning Tacking stitch distance (distance) P 6.2/P 7.2 0.2 … 1.0 mm • Distance in y-direction for a double stitch Tacking length (length) P 6.3/P 7.3 0.6 … 6.0 mm • Length of tacking in y-direction Parameter P7.3 can only be input when upper/lower tacking types are different Tacking width Right offset (Offset r) P 6.4/P 7.4 –1.0 … 1.
Settings via the software 6.6.4 Circular tacking (horizontal) parameters, tacking type D Symbol Parameters Values Meaning Tacking stitch distance (distance) P 6.6/P 7.6 0.3 … 1.0 mm • Distance in y-direction for a double stitch 6.6.5 Cross tacking (vertical) parameters, tacking type E Symbol Parameters Values Meaning Tacking stitch distance (distance) P 6.2/P 7.2 0.2 … 1.0 mm • Distance in y-direction for a double stitch Tacking length (length) P 6.3/P 7.3 0.6 … 6.
Settings via the software Symbol Parameters Values Meaning Tacking width Right offset (Offset r) P 6.4/P 7.4 –1.0 … 1.0 mm • The width of the tacking is defined via the width of the buttonhole. The width of the tacking can be enlarged to the right using the right offset. Tacking width Offset left (Offset l) P 6.5/P 7.5 –1.0 … 1.0 mm • The width of the tacking is defined via the width of the buttonhole. The width of the tacking can be enlarged to the left using the left offset. Speed 200 ...
Settings via the software 6.7 Knit fabric mode Knit fabric mode is for sewing stretchable material. In knit fabric mode, buttonholes are sewn over several times to ensure greater stability. 6.7.1 Basting stitches parameters Symbol Parameters Values Meaning Runs (BS runs) P9.1 0...4 • Number of basting stitch runs Stitch length P 9.2 0.3 … 3.0 mm • Stitch length of basting stitches Thread tension (TT[%]) P 9.3 0...
Settings via the software 6.7.3 Cutting parameters Symbol Meaning || • Cut during both sewing runs :| • Cut on last sewing run |: • Cut on last but one sewing run 6.7.4 Combination options in knit fabric mode Here a straight basting stitch can be combined with a single or double zigzag. A selection can be made as to whether to cut in the last run or last but one sewing run.
Installation 7 Installation WARNING Risk of injury The machine may be installed only by trained specialists. Wear safety gloves and safety shoes when unpacking and installing. 7.1 Checking the scope of delivery The delivery scope will vary according to your order. 1. Check that all parts required are present. 7.2 Removing transport securing devices All transport securing devices must be removed prior to setup. 1.
Installation 7.5 Connecting the suction device The vacuum in the infeed device fixes the sewing material once it is aligned. The infeed device has been prepared for connection to a vacuum system at the customer's site. If no vacuum system is available at the site, the optionally available vacuum fan and vacuum distributor need to be ordered as additional equipment. 1. Connect the vacuum hose of the customer's vacuum system or the vacuum distributor to the intake nozzle. 7.
Installation 7.8 Pneumatic connection 7.8.1 Fitting the maintenance unit The pneumatic unit is an additional component that is not part of the standard delivery package. ATTENTION Machine damage possible due to incorrect pressure. The system pressure for the pneumatic unit is 8 - 10 bar. Make sure that the system pressure is set correctly before fitting the pneumatic unit.
Installation 7.8.2 Setting operating pressure ATTENTION Machine damage possible due to incorrect pressure. The operating pressure for the pneumatic unit is 6 bar. Make sure that the operating pressure is set correctly before putting the machine into operation. Figure 18: Setting operating pressure q 6 4 8 2 10 0 w (1) - Adjustment knob (2) - Pressure indicator 1. Pull the adjustment knob (1) up. 2.
Installation 7.10 Sewing test Conduct a sewing test before commissioning. Adjust the machine to the sewing material requirements. To do this, read the corresponding sections in Operation. CAUTION Risk of injury from the point of the needle and moving parts Switch off the sewing machine before replacing the needle, insert the thread, insert the hook thread reel, adjust the hook thread tension and the thread regulator. 1. Insert needle. 2. Thread needle thread. 3. Thread hook thread. 4.
Installation 54 Operating Instructions 841 - 00.
Disposal 8 Disposal Do not dispose of the machine in the general household waste. The machine must be disposed of in an appropriate and proper manner according to national regulations. ATTENTION Risk of environmental damage due to incorrect oil disposal Improper disposal of the machine can result in serious environmental damage. ALWAYS observe the legally prescribed regulations for disposal of oil.
Disposal 56 Operating Instructions 841 - 00.
Troubleshooting 9 Troubleshooting Number Location Description Possible cause Remedial action 1052 Sewing motor Excess current • Sewing motor cable • Sewing motor • Controller • Check the sewing motor cable • Check the sewing motor • Check the controller 1053 Sewing motor Excess voltage • Mains voltage too high • Check the mains voltage 1055 Sewing motor Overload • Sewing motor (blocked/not • Check the sewing motor moving freely) • Check the controller • Controller 1056 Sewing motor E
Troubleshooting Number Location Description Possible cause Remedial action 2158 Stepper motor x-axis Speed • Stepper motor • Controller • Check the stepper motor • Check the controller 2301 Stepper motor z-axis Referencing: Timeout • Reference switches • Stepper motor • Controller • Check the reference switch • Check the stepper motor • Check the controller 2352 Stepper motor z-axis Excess current • Stepper motor • Controller • Check the stepper motor • Check the controller 2353 Steppe
Troubleshooting Number Location Description Possible cause Remedial action 4307 Memo dongle Wrong class • Wrong class dongle attached • Attach correct dongle • Format dongle 5101 Contour data management EEPROM not initialized • Controller • Check the controller • Controller does not contain • Install a machine program a machine program 5104 Contour data management EEPROM checksum fault • Controller 5301 Contour data management No contour data • Cutting length smaller than • Change para
Troubleshooting 60 Operating Instructions 841 - 00.
Subject to design changes – Printed in Germany – © Dürkopp Adler AG – Original Instructions – 0791 841740 EN – 00.0 – 09/2014 DÜRKOPP ADLER AG Potsdamer Str. 190 33719 Bielefeld Germany Phone +49 (0) 521 925 00 E-Mail: service@duerkopp-adler.com www.duerkopp-adler.
